Maintenance Manual

Transcript

C42 Maintenance Manual Issue 4 C42 Maintenance Manual Page 1 of 59 C42 Maintenance Manual This Manual belongs to aircraft reg : ______________________ ___________ Type IKARUS C42 : Serial No. Manufacturer: _____________________ Red Aviation Hangar 6 Halfpenny Green Airport Bobbington DY7 5DY Tel. +44 (0)1384 221600 This handbook should be kept with the aircraft. C42 Maintenance Manual Page 2 of 59 1 CONTENTS CONTENTS ....................................................................................................................................3 ISSUE AMENDMENTS...................................................................................................................4 GENERAL.......................................................................................................................................5 3.1 Drawing and Dimensions ....................................................................................................6 3.2 Equipment list .........................................................................................................................7 3.3 Sources for Spare parts........................................................................................................8 3.4 Consumable items................................................................................................................9 3.5 Recommended Stocking List.............................................................................................9 3.6 Engine Specifications.........................................................................................................10 3.7 Air pressure for tyres and shock absorber: ...................................................................10 3.8 Approved Oils/Coolants and Capacities ....................................................................10 3.9 Recommended fastener torque values .......................................................................11 3.10 Defect and Fault Reporting ........................................................................................12 4 Weight & Balance ...................................................................................................................13 4.1 Weight and Balance Calculations.................................................................................13 4.2 Conditions of Weighing .....................................................................................................14 5 INSPECTIONS..............................................................................................................................15 5.1 Daily Inspection / Pre-flight Inspection..........................................................................15 5.2 25 hour inspection...............................................................................................................16 5.3 50-Hour Inspection ..............................................................................................................17 5.4 100-Hour or Annual Inspection ........................................................................................18 6 LANDING GEAR ........................................................................................................................19 7 STRSSTRUCTURES........................................................................................................................19 8 ENGINE........................................................................................................................................21 9 FLIGHT CONTROLS....................................................................................................................22 10 BRAKE SYSTEM ...........................................................................................................................31 11 FUEL SYSTEM ...............................................................................................................................33 12 PROPELLERS ...............................................................................................................................37 13 UTILITY PARTS ..............................................................................................................................39 14 INSTRUMENTS AND AVIONICS ...............................................................................................40 15 ELECTRICAL SYSTEM .................................................................................................................41 16 STRUCTURAL REPAIRS...............................................................................................................45 17 JACKING THE AIRCRAFT .........................................................................................................47 18 RIGGING THE WINGS ...............................................................................................................48 19 WING FOLD ................................................................................................................................52 19.1 Fitting the wing fold mechanism................................................................................52 19.2 Folding The Wings...........................................................................................................54 20 DOOR REMOVAL......................................................................................................................56 21 PAINTING AND COATINGS.....................................................................................................57 22 FEEDBACK FORM ......................................................................................................................58 23 ANNEX A – MANDATORY MODIFICATIONS........................................................................59 24 ANNEX B - APPROVED OPTIONAL MODIFICATIONS ........................................................59 25 ANNEX C - WEIGHING INFORMATION.................................................................................59 1 2 3 C42 Maintenance Manual Page 3 of 59 2 Issue No. ISSUE AMENDMENTS Change/Description Date Initial draft issue 1 12/09/05 2 Parts stocking list 21/09/05 3 Performance Aviation details added. 4/8/2011 4 Red Aviation details added. 23/1/2015 1 C42 Maintenance Manual Page 4 of 59 Signature 3 GENERAL It is vital that this manual is read in conjunction with the Pilot Operators Handbook (P.O.H.) that was issued with the aircraft. The P.O.H. contains all pertinent data that relates to operating weights and limitations of that particular aircraft. This hand book covers maintenance, servicing and other items that relate to aircraft sold in more than one country and aircraft that have differing limitations. If you do not have the P.O.H. of the aircraft that requires maintenance do not proceed until this document is available. It can be obtained directly from the manufacturer -Red Air UK. SERIOUS INJURY OR DEATH MAY RESULT FROM THE INCORRECT APPLICATION OF THIS MANUAL. C42 Maintenance Manual Page 5 of 59 3.1 Drawing and Dimensions C42 Maintenance Manual Page 6 of 59 3.2 Equipment list This equipment list gives an approximate description of the C42 aircraft. Design: Landing gear, fuselage, wings, struts and empennage are of certified, high-strength aluminium tubing. Fittings and screws are of stainless steel or of high-strength standard elements. Wings and empennage are covered with lattice cloth foil (GT-foil) with high tensile strength and UV treated. All fairings in glass-fibre/epoxy resin and Kevlar Aramid Honeycomb. Cabin windshields made of Makrolon. Removable wings. Power Plant: 4 cylinder, 4-stroke liquid-cooled / air-cooled Rotax 912 UL boxer motor 58 kW/80 hp or 100hp, with electrical starter, dual electronic ignition, integrated reduction gear box, ground adjustable 3-blade or 2-blade propeller. Standard Glass-fibre fairings (as above), (partly as sandwich construction). Highly effective hydraulic disc brakes with parking brake. UV-stable GT-foil coverings for wings and empennage available (std colour: white). High-lift flaps with separate aileron. Stick mounted electric elevator trim. Gas-pressure spring assembly for cabin doors. Flight instruments: Altimeter, airspeed indicator, compass, bank indicator. Engine instruments: RPM indicator, oil pressure indicator, oil temperature gauge, water temperature gauge, fuel gauge. Cabin heating, adjustable fresh-air inlets for both seats. 65 litre Fuel Tank. High power/ low weight sealed lead acid battery, 12 Volt power socket. Seat Cushions, map pockets, door locks, floor mats. Nose and main wheel fairings. Red or Blue stripe. Radio Antenna. Equipment: Optional Items Propellors Airframe C42 Maintenance Manual Refer to POH for types cleared for use Carbon Fibre Shells (saves 4kg) Wingtips Lightweight Version (White only) Wingtips Coloured (Red or Blue) VLA only Scratch Resistant Front Window Cabin Ceiling Window Cabin Ceiling Window - Bronzed Folding Wing Kit (supplied separately) Main Wheel Strut Fairings Suspension Points (Hanging Storage) Page 7 of 59 Instruments Vertical Speed Indicator - approx 80mm Vertical Speed Indicator - approx 55mm Operating Hours Meter Artificial Horizon (Vacuum or electric) Vertical Card Compass 57mm ) Fuel Computer (Fuel CAT) Master Caution Warning System (Comco Design) VHF Comms Filser ATR500 radio (inc intercom) Filser ATR600 radio (inc intercom) Funk ATR 833 radio (inc intercom) Filser TRT 600 Mode S/C Transponder Funk TRT 800 Mode S/C Transponder Microair radio 760 Microair Transponder T2000 mode C Exterior Lighting Nose Wheel Landing Light (single bulb) Strobe Light - single light mounted on Fin Exterior fitments Glider towing Kit 3.3 Sources for Spare parts Spare parts for the C42 can be obtained from the following sources :Manufacturer: Red Aviation Halfpenny Green Airport Bobbington Stourbridge DY7 5DY Great Britain Tel. +44 (0)1384 221600 C42 Maintenance Manual Page 8 of 59 3.4 Consumable items Tyres, oil, coolant, battery, spark plugs, oil filter, fuel filter, fuses, Part Description Tyres Inner tubes Coolant Engine oil Battery Spark Plugs Oil Filter Fuel Filter 4.00 x 6 4 ply rating 4.00 x 6 angled valves Glycol based @ 50% concentration Shell Advance VSX 4 or Sport 4 12 Volt 8 AH (Hawker) NGK DCPR7E (80hp) NGK DCPR8E (100hp) Rotax 912 825 701 Nylon mesh filter with 8mm connections C42 Maintenance Manual Page 9 of 59 3.6 Engine Specifications The C42 has optional power plants: (i) The Rotax 912UL horizontally opposed, 4 cylinder 4 stroke engine, with water cooled heads and oil and air cooled cylinders; it has a capacity of 1211 cc and develops 80hp at 5800 rpm. The power is delivered to the fixed pitch propeller via a gearbox having a ratio of 2.27:1. (ii) The Rotax 912ULS, with same configuration to the 912UL, but with a larger capacity of 1352 cc, higher compression ratio and developing 100 hp. Its gearbox has a ratio of 2.43:1. Full descriptions of the engine, its performance and maintenance requirements are to be found in the Rotax manual. Please see the relevant section for Engine limitations. Exhaust system The engine is fitted with a Haggerman Exhaust and Silencer System. system is built largely from stainless steel components. 3.7 3.8 Air pressure for tyres and shock absorber: Main wheels 1.8 - 2.5 bar 26 to 36 psi. Front wheel 1.5 - 1.8 bar 22 to 26 psi. Shock absorbers 29 - 33 bar 425 to 486 psi Approved Oils/Coolants and Capacities Refer to rotax manual C42 Maintenance Manual Page 10 of 59 This 3.9 Recommended fastener torque values Refer to rotax manual Warp Drive 8mm prop bolts torque Neuform 8mm prop bolts torque - 25Nm 27Nm Wing torque settings C42 Maintenance Manual Page 11 of 59 3.10 Defect and Fault Reporting Any defects found during inspections, routine maintenance or at any other time must be rectified before the next flight. All defects should be reported to the manufacturer using the form supplied at the end of this document. C42 Maintenance Manual Page 12 of 59 4 Weight & Balance The aircraft should be maintained in a configuration which meets the weight and balance criteria set out below and in the P.O.H.. Aircraft flying under BCAR Section S Max Gross weight is 450kgs (990Lbs), or 472.5kg with an approved ballistic recovery system fitted. Note :For detailed weight and balance limitations you must refer to the P.O.H. appropriate to the aircraft in question. 4.1 Weight and Balance Calculations The centre of gravity is measured in mm behind the zero datum. Zero datum is the leading edge root. The aircraft’s empty weight and cg are derived first: Place the aircraft in a level position on three scales, such that the stabilizer is horizontal, as shown below. Push down on the rear fuselage, just in front of the tail, and chock the nose wheel to level the aircraft. Record the reading of each scale. G1 G2 = GL + GR x a b Calculate the position of the empty cg, from the formula: X=a− G1 × b = ................mm G1 + G 2 (a and b are values to be measured for the specific aircraft). Insert the values for total empty weight, (G1 + G2) and cg distance aft of datum, (X), into the table below. Multiply Empty Weight (kg) by cg distance aft of datum (mm) to derive empty weight moment (kg.mm) in the last column. Complete the remaining weights for seat loads, fuel and baggage and multiply these by the lever arm lengths (given below). Add up the weights and moments, then divide the total weight by the total moment to give laden cg location aft of datum. C42 Maintenance Manual Page 13 of 59 Loading plan Position weight x lb (kg) lever arm in. (mm) = moment lb in (kgmm) Empty weight 1. Seats 15.7 (400) 2. Fuel 37.4 (950) 3. Baggage 51.2 (1300) T otal W eight lb (kg) T otal Moment T otal Moment centre of gravity CG = lb in (kgmm) lb in (kgmm) ------------------------------------------ = T otal W eight lb (kg) in (mm) Centre of gravity range is dependant on aircraft model. Refer to TADS. 4.2 Conditions of Weighing The dry empty weight of the aircraft is defined under the following conditions: All normal installed equipment fitted. Oil and coolant levels normal. No usable fuel. Note: Remaining within the Maximum Take-off Weight (MTOW) as specified in the P.O.H. is the pilot’s responsibility. C42 Maintenance Manual Page 14 of 59 5 5.1 INSPECTIONS Daily Inspection / Pre-flight Inspection 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21 22. 23. Engine and cowling secure and undamaged. Check coolant level correct. Check oil level within limits.* Propeller clean and undamaged1, bolts secure. Front gear; tyre pressure, tyre condition and tyre creep. Left main gear; tyre pressure and condition. Left side wing, structure and covering. Left wing strut attachment secure. Left aileron, control linkage and hinges secure. Left flap, control linkage and hinges secure. Left side of the fuselage, undamaged Tail group secure and surfaces undamaged. Elevator hinges and control linkage secure. Trim tab and linkage secure. Rudder hinges and control cables secure. Repeat items 4 thro’ 9 for right side. Fuel filler cap secure. Windscreen clear and undamaged. ASI pitot unobstructed and fully extended. Cockpit area inside and out, check controls full movement, free and correct sense. Instruments serviceable. Open fuel tank sump drain and check for contamination. Check tank water drain for leaks. *When checking the oil level it may be necessary to pump the oil back into the reservoir to obtain a correct reading and to avoid overfilling. This can be done by removing the oil filler cap and ensuring the master switch and magnetos are off and rotating the propeller ONLY in the operating direction until a gurgling sound is heard from the reservoir tank. With composite propellers, minor damage to the external surface, such as a deep scratch which breaches the outside fabric, can result in significant loss of strength and a dangerous condition. For this reason it is important to inspect the blades carefully before flight. Look particularly for scratches along the chord of the blade which may have severed one or more yarns of fibre. When in doubt, seek expert advice. 1 • Neuform propellers must be returned to Neuform in Germany for an inspection every 500 hours or 2 years whichever comes first. Please refer to your propeller operating manual. C42 Maintenance Manual Page 15 of 59 Periodic Maintenance and Inspection 5.2 25 hour inspection Engine: Check 25 hour inspection items in accordance with the ROTAX manual. Fuel system 1. 2. Check tank internally for cleanliness. Check fuel filter for cleanliness. Airframe 1. 2. 3. 4. Check control stick for freedom without undue friction. Check safety lock plates at the bearings at front and rear ends of control stick torsion tube. Check that rod end bearings on elevator push rods suffer no bending at each extreme lateral position of stick (aileron limits). Check all lock nuts for tightness. Wing 1. 2. 3. 4. Check internal bracing wires for adequate tension. Check freedom of ailerons. Check aileron and flap hinges for wear. Check aileron and flap hinge bolts for tightness (cannot rotate) Tail Empennage 1. 2. 3. 4. Check rudder hinges for wear. Check elevator hinges for wear. Check rudder and elevator hinge bolts for tightness (cannot rotate) Check rudder cables for wear at fairleads. C42 Maintenance Manual Page 16 of 59 5.3 50-Hour Inspection Engine and Fuel System Check inspection items in accordance with the ROTAX manual. Additionally to 25 hours inspection 1. 2. 3. 4. 5. 6. 7. Check rudder and aileron cables for wear and damage. Check brake pads, brake disks and brake function. Lubricate the nose leg bearings with a grease gun at the upper and lower grease nipples. Check rudder cable tension, 25 to 35 kgf. Check aileron cable tension, 18 to 24 kgf Change the fuel filter. Check stub axles for cracks. C42 Maintenance Manual Page 17 of 59 5.4 100-Hour or Annual Inspection Engine and Fuel System Perform 50 hours checks in accordance with ROTAX manual. Additionally to 50 hours inspection 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Clean, grease and check security of ball joints on steering rods at foot pedals and operating bar of front wheel. Clean, grease and check security of rod end bearings at stick torsion tube. Clean grease and check freedom of throttle control; ensure that the cable cannot stick, even when closed slowly. Clean, grease and check security of all ball and fork hinges at each aileron push rod end. Check all hinges for excess play. Clean and grease all hinges and remove rudder to check clevis pins for excess wear. Check all lock nuts for proper installation; check 2 threads showing. Check central and internal wing-mounted aileron bellcranks for freedom and security. Clean and grease bellcrank ball connections, and, if necessary, bellcrank bearings. Check cross bolt and connections of elevator motion reversal lever for security and wear. (Mounted on rear fuselage). Check bearing of reversing lever for wear and freedom. Clean and grease central bearing. Clean, grease and check security of rod-end bearings of elevator push rods; tighten and Loctite locking nuts. C42 Maintenance Manual Page 18 of 59 6 LANDING GEAR The tricycle undercarriage has suspension on all wheels and damping on the main wheels. The front fork is directly connected to the rudder pedals. Hydraulic disc brakes operate on the main wheels only. Main wheels suspension stiffness can be adjusted by varying the air pressure in the damper units via the valves in their bases. A special high pressure pump is required for this purpose. Shock absorbers 29 - 33 bar 425 to 486 psi The nose leg upper and lower bearings have grease nipples for lubrication using a grease gun. Maintenance of the landing gear is in accordance with the Inspection schedule in Section 1 – Inspections. Main gear suspension strut Nose leg lubrication points Grease nipple Air valve Grease nipple 7 C42 Maintenance Manual Page 19 of 59 S T R S STRUCTURES Description A 6.5” (165 mm) diameter aluminium tube runs from nose to tail and carries all the major assemblies: engine, seats, undercarriage, fuel tank, and tail empennage. The cockpit structure, consisting of a thin walled aluminium tube frame, includes a welded aluminium box-section frame at its top to which the wing spars’ roots attach, and which provides compression load carry-through for both spars. The composite seats are supported around their edges by attachment to the cockpit frame. Around the outboard edges of the seats, some of these loads are passed via the composite lower fairing to a lateral beam consisting of a 2.2” (56mm) reinforced box section. The ends of this beam accommodate the wing struts and withstand tension loads from them. All load carrying (structural) members of the airframe are aluminium alloy tubes; most of which terminate in spherical bearings. Maintenance of the structure is in accordance with the Inspection schedule in Section 1 – Inspections. All defective structural components must be replaced with new parts obtained only from your dealer or the manufacturer. Do not use pattern parts. Never straighten bent tubes or bracket assemblies, replace with new parts only. Any defects must be reported to the manufacturer. C42 Maintenance Manual Page 20 of 59 8 ENGINE The C42 can be fitted with either the Rotax 912UL or Rotax 912ULS engines. Refer to the manual supplied with the aircraft for the correct maintenance procedures. Maintenance of the engine is in accordance with the Inspection schedule in Section 1 – Inspections. All defective engine components must be replaced with new parts obtained only from the manufacturer or Rotax. Do not use pattern parts. Any defects must be reported to the manufacturer. C42 Maintenance Manual Page 21 of 59 9 FLIGHT CONTROLS Pitch A central control stick, accessible by both occupants, is located over the fuselage between the seats. Fore and aft movement of this stick is transferred, via longitudinal push tubes, to a motion reversal lever installed midway between the cockpit and tail. This installation also accommodates the pitch stops. A second push tube, of similar length, runs from this lever to the elevator horn. A rearward movement of the stick lifts the elevator; forward movement depresses it. Each push rod terminates in a spherical bearing (rose joint) maintaining loads through the centres of the tubes. The threaded roots of these fittings can be susceptible to failure if bending loads are applied; it is important to ensure complete freedom of the joints at extremes of their movements, such that bending loads cannot be applied. Elevator reversal relay Adjustment point Elevator stop Elevator horn Adjustment point Elevator horn C42 Maintenance Manual Page 22 of 59 Roll The stick is also connected to a torque tube mounted on top of the fuselage tube between the seats, and turning on a Rose joint at each end. The rear of the torque tube carries a pair of horns from which run control cables, one for each side. These cables are led behind and over the cockpit, via pulleys, to a central bellcrank. From here, motion is transferred via push tubes to a bellcrank in each wing, mounted on a wing compression strut forward of the aileron. A second tube links this bellcrank to the aileron horn. The geometry of the aileron control system produces some asymmetry in the deflections of the ailerons, effectively eliminating adverse yaw. Movement of the stick to the right results in a lifting of the right hand aileron and depression of the left, and vice versa. Control stick Control stick Aileron torque tube, horns and control cables Aileron torque tube Aileron control cables C42 Maintenance Manual Page 23 of 59 “A” frame aileron bellcrank Aileron control cables Aileron control horn and pushrod Adjustment point C42 Maintenance Manual Page 24 of 59 Yaw Dual rudder pedals are mounted on common torque tubes, bearing in bushes installed directly into the fuselage tube. Control cables run from points near the top of the pedals’ arms direct to the rudder horns. Push rods connected to arms on the front fork, permit direct steering to be made via the rudder pedals. These push rods are curved to permit slight bending in the event of large opposing forces from two pilots being applied to the rudder pedals. In this event, a large proportion of the load is borne by the rudder cables themselves. Two light springs are fitted to the rudder pedals to aid centring. Pushing the right rudder pedal forward results in the rudder moving to the right; pushing the left pedal forward results in the rudder moving to the left. Rudder pedals Rudder return cable Adjustment point Rudder cable Rudder return cable & spring Rudder return spring C42 Maintenance Manual Page 25 of 59 Rudder control horn & stops Rudder horn Rudder horn Rudder stops C42 Maintenance Manual Page 26 of 59 Flaps The flap lever is mounted on the top of the “A” frame in the centre of the cockpit above the pilot’s head. When the flap lever is squeezed by the pilot's thumb it removes a cross-pin from indents on a plate, thus allowing the flaps to be operated. Upon release of the detent lever the cross-pin can engage in the detent plate once again to hold the flaps in position. Adjustment of the flaps is at the end of the pushrods. Neutral flap setting is aligned with neutral aileron position. Flap range is pre-set by the detent plate. Flap lever “A” frame Flap lever Indent plate Flap drivers & pushrods Flap driver Pushrod Adjustment point C42 Maintenance Manual Page 27 of 59 Flap driver Flap driver locating tube Driver tube located onto flap trailing edge tube Spring loaded locking pin or bullet C42 Maintenance Manual Page 28 of 59 Trim An electric pitch trim system is controlled from a rocker switch on the control switch. Pressing the top of the rocker switch lifts the trailing edge of the trim tab and results in a pitch down trim; pressing the bottom depresses the trim tab and results in a pitch up trim. The switch controls a small servo motor near the trailing edge of the fixed stabilizer. A short push rod runs from this servo motor to the trim tab horn. Raising the trim tab in flight results in a down deflection of the trailing edge of the elevator and a nose down pitch. A panel-mounted meter indicates trim position. If the trim runs away to one extreme or fails in one position, no undue stick force is required to maintain control. Trim adjustment buttons Trim indicator Elevator trim tab Trim tab Pushrod Adjustment point C42 Maintenance Manual Page 29 of 59 Control Surface Deflections Aileron Up 20 ±2° or 85 mm, ±9 mm measured 250 mm from the hinge axis. Down 14° ±2° or 60 mm, ±9 mm measured 250 mm from the hinge axis. Area 0,58 m2 per side. Elevator Up 30° ±3° or 205 mm + 21 mm measured 410 mm from the hinge axis. Down 20° ±3°. Or 140 mm + 21 mm measured 410mm from the hinge axis. 0.82 m2 total Area Rudder L/R 32° ±3° or 217 mm + 21 mm measured 410mm from the hinge axis. Area 0.44 m2 Fin Area 0.61 m2 Stabilizer Area 1,42 m2 total Flaps - 4.5° -15° Area Elevator Trim Tab C42 Maintenance Manual Up - 42° Relative to the fuselage tube. 0.46 m2 per side. 1 to 5º Down 25º±3º (relative to elevator) Page 30 of 59 10 BRAKE SYSTEM The control stick carries a brake lever with an integrated master cylinder. Hydraulic lines carry pressure to a small disc brake on each of the main wheels. The brakes work together. Maintenance of the brake system is in accordance with the Inspection schedule in Section 1 – Inspections. Brake system Control stick Brake lever Brake master cylinder Hydraulic Brake line Main wheel calipers Brake lever & adjustment screw Safety ring Adjustment screw Brake lever Locking clip C42 Maintenance Manual Clevis pin Page 31 of 59 Control stick Replenishing the brake fluid Remove the clevis pin and the brake lever. Using some thin nose pliers remove the small aluminium cup and then very carefully (try using 2 x pairs thin nose pliers) lift out the grey seal. This is quite brittle so take care. Then obtain a small syringe or pipette and drop a small amount of LHM hydraulic fluid to raise the fluid level. It is essential to use the correct fluid. Use LHM hydraulic fluid commonly used in Citroen vehicles. CAUTION: DO NOT USE AUTOMOTIVE BRAKE FLUID Re-fit the grey seal and the aluminium cup. Before re-fitting the brake lever use a small allen key to wind out the adjusting plunger a few turns. Re-fit the brake lever and clevis pin ensuring to re-adjust the allen key for the plunger. Replacing the brake pads Remove each wheel spat and chock the wheels. Ensure the parking brake is off and using an allen key unwind the adjusting plunger a few turns. Remove the 6mm caliper bolts. Be careful to note the position of any shims fitted. Lift off the caliper being careful not to kink or distort the brake fluid line. Remove the split pin and lift out each brake pad. Using a small piece of wood push or gently lever back the caliper pistons. Re-fit the new pads making sure to also fit the new split pin. Re- fit the calliper over the disc and onto the mounting bracket. Secure the caliper bolts making certain to re-fit any shims fitted. Re-fit the wheel spats. Operate the brake lever to seat the new pads in the calipers and adjust the plunger to acquire the necessary friction. Brake disc & caliper Brake disc Brake line Brake pad retaining split pin Brake caliper C42 Maintenance Manual Page 32 of 59 11 FUEL SYSTEM Maintenance of the fuel system is in accordance with the Inspection schedule in Section 1 – Inspections. All defective fuel system components must be replaced with new parts obtained only from the manufacturer or Rotax. Do not use pattern parts. Any defects must be reported to the manufacturer. Fuel System Vapour return line Left carb Filler nozzle Right carb Fuel tank vent Fuel tap Electric fuel pump Sump Mechanical fuel pump Drain valve Firewall Andair check valve Fuel filter Fuel tank components Vent tube Fuel gauge sender Vapour return tube C42 Maintenance Manual Page 33 of 59 Filler nozzle Fuel tank Andair Check Valve Electric fuel pump & Andair check valve Electric fuel pump Andair check valve Electric fuel pump by-pass pipe C42 Maintenance Manual Page 34 of 59 Fuel tap Fuel filter Vapour Return C42 Maintenance Manual Page 35 of 59 Mechanical fuel pump Fuel Flow Checks C42 Maintenance Manual Page 36 of 59 12 PROPELLERS The C42 can be supplied with different propellers :For approved propeller types you must consult the POH relevant to aircraft model. All approved types have blades with ground-adjustable pitch and are set to the pitch angles given in the relevant POH. This pitch angle is prescribed at a specific radius from the point at which the blade exits from the hub. The propellers have aluminium alloy hubs machined to close tolerances. This permits secure clamping of the blade roots under the high centrifugal forces experienced by the blades in service. Proper blade root securing bolt tension is essential to maintain this security. Maintenance of the propeller is in accordance with the Inspection schedule in Section 1 – Inspections. All defective propeller components must be replaced with new parts obtained only from the manufacturer. Do not use pattern parts. With composite propellers, minor damage to the external surface, such as a deep scratch which breaches the outside fabric, can result in significant loss of strength and a dangerous condition. For this reason it is important to inspect the blades carefully before flight. Look particularly for scratches along the chord of the blade which may have severed one or more yarns of fibre. When in doubt, seek expert advice. • Neuform propellers must be returned to Neuform in Germany for an inspection every 500 hours or 2 years whichever comes first. Please refer to your propeller operating manual. Slight adjustment to the pitch of each of the above propellers may be necessary to obtain the correct ground static rpm. An optical tacho on the propeller is the preferred method of measuring the engine speed. C42 Maintenance Manual Page 37 of 59 Warp Drive prop hub Locking tab washer Locking tab washer Warp Drive pitch setting tool Any defects must be reported to the manufacturer. Please see the technical data sheet section of the POH for further information. C42 Maintenance Manual Page 38 of 59 13 UTILITY PARTS Maintenance of utility parts is in accordance with the Inspection schedule in Section 1 – Inspections. All defective utility parts must be replaced with new parts obtained only from the manufacturer. Do not use pattern parts. Any defects must be reported to the manufacturer. Heater System Heater valve knob Cockpit heater tube Push cold Pull hot Firewall Exhaust heat exchanger Cold air intake Outside air vent Heater valve assy Heater valve assembly Cockpit heater Heater tube Heater cable Heater valve C42 Maintenance Manual Heater on / off control Page 39 of 59 14 INSTRUMENTS AND AVIONICS Maintenance of instruments and avionics is in accordance with the Inspection schedule in Section 1 – Inspections. All defective instruments and avionics must be replaced with new parts obtained only from the manufacturer. Do not use pattern parts. Any defects must be reported to the manufacturer Ltd. C42 Maintenance Manual Page 40 of 59 15 ELECTRICAL SYSTEM Please refer to the schematics below. Maintenance of the electrical system is in accordance with the Inspection schedule in Section 1 – Inspections. All defective electrical components must be replaced with new parts obtained only from Red Aviation . Do not use pattern parts. Any defects must be reported to Red Aviation UK Electrical parts Regulator / rectifier Earthing points Starter motor solenoid C42 Maintenance Manual Page 41 of 59 3.4 Consumable items Page 9 of 59 4.00 x 6 4 ply rating 4.00 x 6 angled valves Glycol based @ 50% concentration Shell Advance VSX 4 or Sport 4 12 Volt 8 AH (Hawker) NGK DCPR7E (80hp) NGK DCPR8E (100hp) Rotax 912 825 701 Nylon mesh filter with 8mm connections Description Tyres, oil, coolant, battery, spark plugs, oil filter, fuel filter, fuses, Part Tyres Inner tubes Coolant Engine oil Battery Spark Plugs Oil Filter Fuel Filter C42 Maintenance Manual Appendix 2 – Circuit Diagram – Trim Tab C42 Maintenance Manual Page 43 of 59 Appendix 3 – Circuit Diagram – MIP installation C42 Maintenance Manual Page 44 of 59 16 STRUCTURAL REPAIRS Maintenance of the structural system is in accordance with the Inspection schedule in Section 1 – Inspections. No structural repairs can take place without the direct authorization of the manufacturer. All structural repairs must be completed using only with new parts obtained only from the manufacturer. Do not use pattern parts. Never straighten bent tubes or bracket assemblies, replace with new parts only. Never re-weld any parts. Any defects must be reported to the manufacturer. Fuselage A 165 mm diameter aluminium tube runs from nose to tail and carries all the major assemblies: engine, seats, undercarriage, fuel tank, and tail empennage. The cockpit structure, consisting of a thin walled aluminium tube frame, includes a welded aluminium box-section frame at its top to which the wing spars’ roots attach, and which provides compression load carry-through for both spars. The composite seats are supported around their edges by attachment to the cockpit frame. Around the outboard edges of the seats, some of these loads are passed via the composite lower fairing to a lateral beam consisting of a 56mm reinforced box section. The ends of this beam accommodate the wing struts and withstand tension loads from them. All load carrying (structural) members of the airframe are aluminium alloy tubes; most of which terminate in spherical bearings. Main fuselage tube Seat support tube Main cross beam Main tube C42 Maintenance Manual Throttle link tube Page 45 of 59 Wing The wing has a ladder construction comprising leading and trailing edge tubes, connected by compression struts at intervals along its span. The triangulated wing struts, terminating at a fixed point at the top of the undercarriage, brace the wing against fore and aft loads. In normal +g flight these struts are under tension. In +g flight both leading and trailing edge tubes inboard of the wing struts junctions, experience compression loads from the wing struts, as well as direct bending from lift loads. The wing, tail empennage and all control surfaces are constructed of thin walled aluminium tubing. They are covered by a reinforced polyester fabric, sewn into complete envelopes and fitting tightly over their frames. Wing frames Aft spar Compression strut Aileron bellcrank Fwd spar Undercarriage The tricycle undercarriage has suspension on all wheels and damping on the main wheels. The front fork is directly connected to the rudder pedals. Hydraulic disc brakes operate on the main wheels only. Main wheel suspension stiffness can be adjusted by varying the air pressure in the damper units via the valves in their struts. A special high pressure pump is required for this purpose. Main wheel Nose wheel Nose leg Main gear strut Drag link tube C42 Maintenance Manual Page 46 of 59 17 JACKING THE AIRCRAFT Either of the main wheels can be brought clear of the ground by one person lifting the wing at the top of the wing struts. (Never apply any significant up load to the centre of the struts). The aircraft can then be chocked by placing a wooden block under the bottom part of the stub axle. This is also a suitable jacking point where a second person is not available to lift the wing. The nose wheel is easily lifted by applying a load to the rear fuselage, just forward of the tail. Where one person only is available, place weights on the tail, suitably padded to prevent damage to the fabric, until the nose wheel becomes light. Place a piece of timber under the tail skid, then push the tail down on to it. Add further weights to the tail to stabilise the aircraft in this attitude. Main wheel jacking point Jacking point C42 Maintenance Manual Page 47 of 59 18 RIGGING THE WINGS Before attempting rigging, take a look at the wing roots and the way in which the rigging mechanism works. Note that the fulcrum (the roller bracket) is located near the wing root, and also in line with the rear spar attachment point. The front spar attachment point however is located some way inboard. This means that lifting the wing tip will result in the front spar clearing its fitting before the rear one. This can be used to advantage during rigging. Step 1. Ensure that the spar channels in the cockpit roof are aligned with the top surface of the cockpit roof frame. Lock the controls, place the flap lever in the fully up position and ensure the brake is on. Step 2. Bring the left wing strut into its correct position on the left wing and attach the auxiliary (jury) struts on the front and rear wing struts to the leading and trailing edge fittings. Step 3. If this is the first side to be rigged and the second wing half is still resting on the tail, lift the wing at its tip with one hand. With the other hand, steadily lift the tail so that the aircraft rests on its nosewheel. Step 4. Carry the wing into its 90° position relative to the fuselage, taking care not to damage the door and fuselage with the front spar. Step 5. Turn the wing into a horizontal position and push it gently towards the fuselage Step 6. Lifting the tip, slowly insert the wing roots into position in their channels, leading edge first. It may be necessary to gently rock and twist the wing to engage the spar hooks on to their pins. Step 7. Ensure that front and rear wing spars are properly engaged in their channels. Then insert the lower end of the wing struts into the open box-section end at the top of the shock absorbers. Step 8. Attach front wing bolt and safety pin, using the tool provided. Step 9. Attach rear wing bolt and safety pin. Step10.Attach the strut bolt through the box-section end and lower steel block of the wing struts ends. Install the safety pin. Step11.Check that all three bolts have their safety pins installed. Step12.As a final check, lift the wing at the wing tip to ensure proper attachment of the wing strut block to the box-section end. Step 13.Connect the pitot tube to its fitting situated to the left of the pilot’s headrest. Pull out the pitot tube forwards to its full extent. Step 14.Repeat steps 1 through 12 for the other wing. Now you may remove the control lock. Step15.Attach right and left aileron push rods to the central bellcrank connection. Carefully ensure that the slide mechanisms of the special link connectors are properly engaged (closed and locked). Step 16.On the flap drive tube, take the split sleeve fitted around the sprung taper pins (and through which they protrude), spread it a little, then rotate it over C42 Maintenance Manual Page 48 of 59 the pins. Using this sleeve as an aid, squeeze it, thus compressing the pins. Then move the sleeve so that the drive fitting moves freely on its tube. Step 17.Align the flap root tube and its drive fitting on the fuselage. Slide the flap drive fitting over the junction so that its cutaways engage snugly in the roots of the flap frame tubes and the sprung pins are fully out. Rotate the split sleeve so that its holes align with the tips of the pins again, permitting the pins to spring out fully. Left and right landing flaps must be securely locked and it may be necessary to wiggle the fitting a little to ensure proper engagement, particularly when the aircraft is new. Step 18.Position and fasten the wing centre section (cockpit roof). Wing root Aileron pushrod Forward spar attachment point Fwd spar attachment Wing fwd spar Fwd spar attachment bracket C42 Maintenance Manual Page 49 of 59 Aft spar attachment Aft spar attachment bracket Aileron attachment Aileron pushrods attached to bell crank C42 Maintenance Manual Page 50 of 59 Flap attachment Flap driver attachment point C42 Maintenance Manual Page 51 of 59 19 WING FOLD 19.1 Fitting the wing fold mechanism. The C-42 has an optional folding wing which minimises hangar space. For road transport however you must remove the wings completely. To attach the wings to the folding system: Step 1. Fit the jockey wheel to the stern post, fit the traingular wooden support brackets to the bottom of the tailplane struts, with the aluminium strip uppermost. Step 2. Remove the stop ring from the slide tube in the cockpit roof. Step 3. Place a wing parallel to the fuselage with its tip supported on the tail by the wooden support bracket. (With both wings folded back and supported by the tail, the aircraft will rock back to sit on its tail. With only one wing on the tail, the aircraft can be tipped forward to a stable attitude resting on its nose wheel. Be aware of these movements during rigging and derigging operations. Take care to protect the wing from damage by contact with the ground). Step 4. Lift the wing root and slide the attachment block (roller) 2 inches (5cm) over the slide tube. Step 5. Attach the stop cable on the leading edge to the quick link on the slide tube. Step 6. Attach the stop ring to the end of the slide tube. If both wings are in the folded back position the C42 can be easily moved by one person into a small hangar space. Folded wings C42 Maintenance Manual Page 52 of 59 Wing fold support tube Support tube Support tube guide Support tube guide C42 Maintenance Manual Page 53 of 59 19.2 Folding The Wings If you have this option fitted : Step 1. Apply the brake. Fit the dolly wheel to the stern post. Step 2. Push in the pitot tube on the left wing. Step 3. Remove wing centre section. Step 4. Disconnect the pitot tube from its fitting above the pilot’s seat back. Step 5. Place a triangular wooden support bracket (supplied) on to the lower part of the tailplane strut at each side, with the aluminium strip uppermost. Step 6. Set the flap control in its fully up position. Step 7. Disconnect the landing flaps by first spreading and rotating the aluminium split sleeve on the flap drive fitting. Then push in the spring loaded pins by squeezing the split sleeve. Step 8. With the trailing edge of the flap resting on your shoulder, squeeze the split sleeve with one hand and, holding the knurled ring in the other, push the assembly inboard until it clears the drive tube junction. Lower the flap gently. Step 9. Unlock the aileron push rods from central bellcrank connections. Step 10.Remove the keep rings from the front and rear spar pins and the lower strut pin, at each side, (total 6 rings). Step 11.Unlock the strut block from lower box section end by removing the strut pin, using the special tool provided. Step 12.Unlock the rear wing spar by removing its pin. Step 13.Unlock front wing spar by removing its pin, hold down the top of the screen to prevent damage. Step 14.Close the door. Step 15.Lift the left wing at its wing tip, or strut tops, so that wing strut block leaves the square box-section end. By lifting the wing high you will first disconnect the front spar hook from its pin and frequently the rear spar at the same time. If the rear spar does not disengage, gently rock the wing from side to side, pulling gently and twisting it until it does. Step 16.Pull out the wing until it stops on the stop wire. Ensure that the stop wire runs over the TOP of the aileron operating push tube before folding back the wing. Step 17.Draw back the wing away from the fuselage until the movement is stopped by the stop ring on the slide tube. Step 18.Rotate the wing into a vertical position - underside of the wing to the front; trailing edge down. Always hold the wing tip higher than the root to prevent damage to the door and fuselage with the spars' ends. Step 19.Carry the wing tip back into a position parallel to the fuselage. If the wing has been supported at the strut tops, it will be necessary to set it down and pick it C42 Maintenance Manual Page 54 of 59 up again by its tip for the next step. During this operation, ensure that the wing cannot tip forwards by walking your hands along the leading edge to the tip. Note that the aircraft will tip back upon folding the second wing. Step 20.Separate the Velcro for 2 or 3 inches (50 to 75 mm) along the aileron root at a point where the support bracket meets it. Step 21.Place the wing trailing edge onto the retainer bracket on the tail. Step 22.Remove the pin from the top of each jury strut. Step 23.Rotate the jury struts carefully so that they lie parallel and next to each other. Step 24.Undo the inboard zip on the wing’s lower surface, adjacent to the jury struts. Step 25.Fold in the main struts to lie flat against the lower wing surface. Secure the strut bottom with the bungee attached to the wing root. Step 26.Fold back the right wing according to steps 1 to 25. C42 Maintenance Manual Page 55 of 59 20 • • DOOR REMOVAL Open door and remove safety clip from gas strut and safety ring from rear clevis pin. Place a piece of tape over the hinge bolt to prevent it turning in or out. Gas strut Door hinge Clevis pin Ball joint and safety pin Safety ring • • Carefully supporting the door, unclip gas strut ball joint and remove clevis pin Then slide the door backwards off the front locating spigot. Front locating spigot C42 with doors removed Locating spigot • • • • To re-fit the doors first slide the door onto the front locating spigot. Locate the rear hinge onto the bracket and fit the clevis pin and safety ring. Clip the gas strut onto the ball joint and fit the safety pin. Have your work checked by your local inspector. C42 Maintenance Manual Page 56 of 59 21 PAINTING AND COATINGS Maintenance of the wing and empennage coverings is in accordance with the Inspection schedule in Section 1 – Inspections. All damaged coverings must be replaced using only with new parts obtained only from the manufacturer. Do not use pattern parts. Any defects must be reported to the manufacturer. Cleaning Clean the wing coverings with warm water and a mild detergent, such as washing up liquid, to remove oil. Never use solvents. All metal parts are anodized aluminum or stainless steel and need no special attention. Dirt or mud on wing surfaces should be removed with clean water. Avoid the use of a pressure washer or hose pipe as this can introduce water into places it shouldn’t go, (engine, fuel tank, pitot head, pilot’s seat). Repair Repair even the smallest tears in the covering fabric. Carefully clean the area around the tear, then attach a small patch with contact adhesive covering an area at least 15 mm larger than the damage all round. Alternatively apply a small patch of self-adhesive material. For larger areas of damage, consult the manufacturer. Repair material is available from the manufacturer. C42 Maintenance Manual Page 57 of 59 Red Aviation Technical 22 FEEDBACK FORM Feedback Form Total hours A/C Model / Engine size Aircraft Serial Number Engine Serial Number Propeller Make Name of Owner Maintenance Org. Address Country Post/Zip code Post/Zip code Tel Tel Email Email Which details above should be used for communication Have any changes,modifications or repairs have taken place to this aircraft since manufacture. Owner YES Maintenance Org. NO (If yes please state on a separate sheet the nature of all changes and include photographs) When compiling your report please include, where applicable, the following : 1) Photocopy of the last logbook entry for aircraft and engine services. 2) When the problem occurs, how the problem manifests itsself, any damage caused by this problem, any solutions you have tried to rectify the problem, any factors you think may have contributed to this problem, any photographic evidence that supports your statements. The more data you give us the quicker we can help you. We take the safety and quality of our aircraft very seriously. We value any feedback that helps us promote flight safety and improve the quality of our products. You will get a confirmation of reciept of your feedback form and any resulting action that is to be taken. Date Received Confirmation sent by Action Taken C42 Maintenance Manual Page 58 of 59 Date Action Confirmed to Customer 23 ANNEX A – MANDATORY MODIFICATIONS See TADS BM68 in their latest issue, available online at www.bmaa.org. 24 ANNEX B - APPROVED OPTIONAL MODIFICATIONS See TADS BM68 in their latest issue, available online at www.bmaa.org. 25 ANNEX C - WEIGHING INFORMATION See TADS BM68 in their latest issue, available online at www.bmaa.org. C42 Maintenance Manual Page 59 of 59